US9142658B2

US9142658B2 - Compound semiconductor device and method of manufacturing the same

Info

Publication number: US9142658B2
Application number: US14/032,493
Authority: US
Inventors: Toshihide Kikkawa; Kenji Nukui
Original assignee: Transphorm Japan Inc
Current assignee: Transphorm Japan Inc
Priority date: 2012-09-28
Filing date: 2013-09-20
Publication date: 2015-09-22
Also published as: US20140091365A1; CN103715253B; TWI512974B; TW201417281A; CN103715253A; JP2014072377A

Abstract

A compound semiconductor device includes: a compound semiconductor layer; and a gate electrode formed above the compound semiconductor layer; and a source electrode and a drain electrode formed on both sides of the gate electrode, on the compound semiconductor layer, wherein the source electrode has a plurality of bottom surfaces along transit electrons out of contact surfaces with the compound semiconductor layer, and the plural bottom surfaces are located at different distances from the transit electrons, with the bottom surface closer to the gate electrode being more apart from the transit electrons.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2012-217346, filed on Sep. 28, 2012, the entire contents of which are incorporated herein by reference.

FIELD

The embodiments discussed herein are directed to a compound semiconductor device and a method of manufacturing the same.

BACKGROUND

Applying nitride semiconductors to high-withstand-voltage and high-power semiconductor devices by utilizing their characteristics such as a high saturation electron velocity and a wide band gap has been considered. For example, GaN being a nitride semiconductor has a band gap of 3.4 eV, which is wider than a band gap of Si (1.1 eV) and a band gap of GaAs (1.4 eV), and has high breakdown electric field intensity. This makes GaN very promising as a material of semiconductor devices for power supply realizing a high voltage operation and a high power.

Many reports have been made on field-effect transistors, in particular, HEMTs (High Electron Mobility Transistors) as semiconductor devices using nitride semiconductors. For example, among GaN-based HEMTs (GaN-HEMTs), an AlGaN/GaN HEMT using GaN as an electron transit layer and using AlGaN as an electron supply layer has been drawing attention. In the AlGaN/GaN HEMT, a distortion ascribable to a difference in lattice constant between GaN and AlGaN occurs in AlGaN. Owing to piezoelectric polarization caused by the distortion and spontaneous polarization of AlGaN, high-concentration two-dimensional electron gas (2DEG) is obtained. Therefore, the AlGaN/GaN HEMT is expected as a high-efficiency switch element or a high-withstand-voltage power device for electric vehicles and the like.

[Patent Document 1] Japanese Laid-open Patent Publication No. 2012-134345

A GaN-HEM is expected to have a high withstand voltage of, for example, 400 V or more. There has been a conventional concern about a breakdown of a gate electrode when a high voltage as above is applied to the GaN-HEMT. In recent years, it has come to be found out that a breakdown occurs also in a drain electrode in ohmic-contact with a nitride semiconductor. The breakdown of the drain electrode is ascribable to electric field concentration occurring on an end of the drain electrode. Consequently, electrons and holes are simultaneously generated by an avalanche effect, and the electrons and the holes further continuously cause the cumulative generation of electrons and holes, so that a current rapidly increases to cause the breakdown in the drain electrode. It has been confirmed that this breakdown of the drain electrode occurs both when a recess is formed in the nitride semiconductor and the drain electrode is formed in the recess and when the drain electrode is formed on the nitride semiconductor without a recess being formed.

SUMMARY

A compound semiconductor device according to an aspect includes: a compound semiconductor layer; and a pair of electrodes formed on an upper side of the compound semiconductor layer, wherein one of the pair of electrodes has a plurality of bottom surfaces along transit electrons out of contact surfaces with the compound semiconductor layer, and the plural bottom surfaces are located at different distances from the transit electrons, with the bottom surface closer to the other of the pair of electrodes being more apart from the transit electrons.

A method of manufacturing a compound semiconductor device according to an aspect includes: forming a compound semiconductor layer; and forming a pair of electrodes on an upper side of the compound semiconductor layer, wherein one of the pair of electrodes has a plurality of bottom surfaces along transit electrons out of contact surfaces with the compound semiconductor layer, and the plural bottom surfaces are located at different distances from the transit electrons, with the bottom surface closer to the other of the pair of electrodes being more apart from the transit electrons.

The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A to FIG. 1C are schematic cross-sectional views illustrating a method of manufacturing an AlGaN/GaN HEMT according to a first embodiment in order of steps.

FIG. 2A to FIG. 2C, which are continued from FIG. 1A to FIG. 1C, are schematic cross-sectional views illustrating the method of manufacturing the AlGaN/GaN HEMT according to the first embodiment in order of steps.

FIG. 3A to FIG. 3C, which are continued from FIG. 2A to FIG. 2C, are schematic cross-sectional views illustrating the method of manufacturing the AlGaN/GaN HEMT according to the first embodiment in order of steps.

FIG. 4 is a characteristic view illustrating a result when a potential state of a drain electrode at the time of the application of a high operating voltage (gate-drain voltage) is studied by simulation, regarding an AlGaN/GaN HEMT according to a comparative example 1.

FIG. 5 is a characteristic view illustrating a result when a potential state of a drain electrode at the time of the application of a high operating voltage (gate-drain voltage) is studied by simulation, regarding an AlGaN/GaN HEMT according to a comparative example 2.

FIG. 6 is a characteristic view illustrating a result when a potential state of a drain electrode at the time of the application of a high operating voltage (gate-drain voltage) is studied by simulation, regarding the AlGaN/GaN HEMT according to the first embodiment.

FIG. 7A to FIG. 7C are schematic cross-sectional views illustrating main steps of a method of manufacturing an AlGaN/GaN HEMT according to a second embodiment.

FIG. 8A to FIG. 8C, which are continued from FIG. 7A to FIG. 7C, are schematic cross-sectional views illustrating main steps of the method of manufacturing the AlGaN/GaN HEMT according to the second embodiment.

FIG. 9A and FIG. 9B, which are continued from FIG. 8A to FIG. 8C, are schematic cross-sectional views illustrating main steps of the method of manufacturing the AlGaN/GaN HEMT according to the second embodiment.

FIG. 10A to FIG. 10B, which are continued from FIG. 9A and FIG. 9B, are schematic cross-sectional views illustrating main steps of the method of manufacturing the AlGaN/GaN HEMT according to the second embodiment.

FIG. 11A to FIG. 11C are schematic cross-sectional views illustrating main steps of a method of manufacturing an AlGaN/GaN HEMT according to a third embodiment.

FIG. 12A and FIG. 12B, which are continued from FIG. 11A to FIG. 11C, are schematic cross-sectional views illustrating main steps of the method of manufacturing the AlGaN/GaN HEMT according to the third embodiment.

FIG. 13 is a characteristic chart representing results when a change in a drain current is studied by simulation, with a drain voltage being changed in a pinch-off state, regarding the AlGaN/GaN HEMTs according to the first, second, and third embodiments based on comparison with the comparative examples.

FIG. 14 is a connection diagram illustrating a schematic structure of a power supply circuit according to a fourth embodiment.

FIG. 15 is a connection diagram illustrating a schematic structure of a high-frequency amplifier according to a fifth embodiment.

DESCRIPTION OF EMBODIMENTS First Embodiment

In this embodiment, an AlGaN/GaN HEMT of a nitride semiconductor is disclosed as the compound semiconductor device.

FIG. 1A to FIG. 3C are schematic cross-sectional views illustrating a method of manufacturing the AlGaN/GaN HEMT according to the first embodiment in order of steps.

First, as illustrated in FIG. 1A, a compound semiconductor stacked structure 2 is formed on, for example, a Si substrate 1 as a growth substrate. As the growth substrate, a SiC substrate, a sapphire substrate, a GaAs substrate, a GaN substrate, or the like may be used instead of the Si substrate. Conductivity of the substrate may be either semi-insulating or conductive.

The compound semiconductor stacked structure 2 includes a buffer layer 2 a, an electron transit layer 2 b, an intermediate layer 2 c, an electron supply layer 2 d, and a cap layer 2 e.

Two-dimensional electron gas (2DEG) being transit electrons is generated in the vicinity of an interface of the electron transit layer 2 b, with the electron supply layer 2 d (to be exact, the intermediate layer 2 c). This 2DEG is generated based on a difference in lattice constant between a compound semiconductor (here GaN) of the electron transit layer 2 b and a compound semiconductor (here AlGaN) of the electron supply layer 2 d.

In more detail, on the Si substrate 1, the following compound semiconductors are grown by, for example, a MOVPE (Metal Organic Vapor Phase Epitaxy) method. A MBE (Molecular Beam Epitaxy) method or the like may be used instead of the MOVPE method.

On the Si substrate 1, AlN with an about 100 nm thickness, i (intentionally undoped)-GaN with an about 1 μm thickness, i-AlGaN with an about 5 nm thickness, n-AlGaN with an about 30 nm thickness whose Al composition is, for instance, about 20%, and n-GaN with an about 3 nm thickness are sequentially grown. Consequently, the buffer layer 2 a, the electron transit layer 2 b, the intermediate layer 2 c, the electron supply layer 2 d, and the cap layer 2 e are formed. As the buffer layer 2 a, AlGaN may be used instead of AlN, or GaN may be grown by low-temperature growth.

As a growth condition of AlN, mixed gas of trimethylaluminum (TMA) gas and ammonia (NH₃) gas is used as source gas. As a growth condition of GaN, mixed gas of trimethylgallium (TMG) gas and NH₃gas is used as source gas. As a growth condition of AlGaN, mixed gas of TMA gas, TMG gas, and NH₃gas is used as source gas. Depending on the compound semiconductor layer that is to be grown, whether or not to supply the TMA gas being an Al source and the TMG gas being a Ga source and their flow rates are appropriately set. A flow rate of the NH₃gas being a common source is set to about 100 ccm to about 10 LM. Further, growth pressure is set to about 50 Torr to about 300 Torr, and growth temperature is set to about 1000° C. to about 1200° C.

In order to grow n-AlGaN of the electron supply layer 2 d and n-GaN of the cap layer 2 e, for example, SiH₄gas containing, for instance, Si is added as n-type impurities to the source gas at a predetermined flow rate, so that AlGaN and GaN are doped with Si. A doping concentration of Si is set to about 1×10¹⁸/cm³to about 1×10²⁰/cm³, for example, set to about 5×10¹⁸/cm³.

Subsequently, element isolation structures 3 are formed as illustrated in FIG. 1B.

In more detail, a resist is first applied on a surface of the compound semiconductor stacked structure 2. The resist is processed by lithography, whereby openings from which portions, of the surface of the compound semiconductor stacked structure 2, corresponding to planned element isolation positions are exposed are formed in the resist. Consequently, a resist mask having the openings is formed.

By using this resist mask, the planned element isolation positions of the cap layer 2 e, the electron supply layer 2 d, and the intermediate layer 2 c are dry-etched to be removed until a surface of the electron transit layer 2 b is exposed. Consequently, element isolation recesses 2A from which the planned element isolation positions of the surface of the electron transit layer 2 b are exposed are formed. As an etching condition, inert gas such as Ar and chlorine-based gas such as Cl₂are used as etching gas.

By using the resist mask again, argon (Ar), for instance, is injected to element isolation regions of the electron transit layer 2 b exposed from the openings. Consequently, the element isolation structures 3 are formed in the electron transit layer 2 b. The element isolation structures 3 demarcate an active region on the compound semiconductor stacked structure 2.

Incidentally, instead of the above injection method, a STI (Shallow Trench Isolation) method, for instance, may be used for the element isolation. At this time, chlorine-based etching gas, for instance, is used for dry-etching of the compound semiconductor stacked structure 2.

The resist mask is removed by ashing using oxygen plasma or by wetting using a predetermined chemical solution.

Subsequently, as illustrated in FIG. 1C, a protective insulating film 4 is formed.

In more detail, a silicon nitride (SiN) with a thickness of about 30 nm to about 500 nm, for example, about 60 nm is deposited on the compound semiconductor stacked structure 2 by a plasma CVD method, a sputtering method, or the like so as to fill the element isolation recesses 2A on the element isolation structures 3. Consequently, the protective insulating film 4 is formed.

The use of SiN for a passivation film covering the compound semiconductor stacked structure 2 can reduce a current collapse.

Subsequently, as illustrated in FIG. 2A, electrode recesses 4A1, 4A2 for a source electrode and a drain electrode are formed in the protective insulating film 4.

In more detail, a resist is first applied on a surface of the protective insulating film 4. The resist is processed by lithography, whereby openings from which a portion corresponding to a region where to form the source electrode and a portion corresponding to a region where to form the drain electrode, in the surface of the protective insulating film 4 are exposed are formed in the resist. Consequently, a resist mask having the openings is formed.

By using this resist mask, the planned electrode formation regions of the protective insulating film 4 are dry-etched to be removed until a surface of the cap layer 2 e is exposed. Consequently, the electrode recess 4A1 from which the region where to form the source electrode in the surface of the cap layer 2 e is exposed and the electrode recess 4A2 from which the region where to form the drain electrode in the surface of the cap layer 2 e is exposed are formed in the protective insulating film 4. For the dry etching, fluorine-based etching gas such as SF₆is used, for instance. This dry etching is required to give as little etching damage as possible to the cap layer 2 e, and the dry etching using the fluorine-based gas gives only a small damage to the cap layer 2 e.

Subsequently, as illustrated in FIG. 2B, a resist mask 11 is formed.

In more detail, a resist is applied on the whole surface. The resist is processed by lithography, whereby an opening 11 a from which the electrode recess 4A1 for the source electrode in the surface of the cap layer 2 e and an opening 11 b from which part of the electrode recess 4A2 for the drain electrode in the surface of the cap layer 2 e are exposed are formed in the resist. Consequently, the resist mask 11 having the

openings

11 a, 11 b is formed.

Subsequently, as illustrated in FIG. 2C, electrode recesses 2B1, 2B2 are formed in the compound semiconductor stacked structure 2.

By using the resist mask 11, the cap layer 2 e and upper layer portions of the electron supply layer 2 d are dry-etched to be removed so that lower layer portions of the electron supply layer 2 d are left. Consequently, in the compound semiconductor stacked structure 2, the electrode recess 2B1 from which the region where to form the source electrode in the lower layer portion of the electron supply layer 2 d is exposed and the electrode recess 2B2 from which the region where to form the drain electrode in the lower layer portion of the electron supply layer 2 d is exposed are formed. For the dry-etching, chlorine-based etching gas such as Cl₂is used, for instance.

The resist mask 11 is removed by ashing using oxygen plasma or by wetting using a predetermined chemical solution.

Subsequently, as illustrated in FIG. 3A, the source electrode 5 and the drain electrode 6 are formed.

In more detail, a resist is applied on the surface of the protective insulating film 4. The resist is processed by lithography, whereby openings from which the electrode recesses 4A1, 2B1 for the source electrode and the electrode recesses 4A2, 2B2 for the drain electrode are exposed are formed in the resist. Consequently, a resist mask having the openings is formed.

By using this resist mask, for example, Ti/Al as an electrode material is deposited on the resist mask including the inside of the openings from which the electrode recesses 4A1, 2B1 and the electrode recesses 4A2, 2B2 are exposed, by a vapor deposition method, for instance. A thickness of Ti is about 30 nm and a thickness of Al is about 200 nm. By a lift-off method, the resist mask and Ti/Al deposited thereon are removed. Thereafter, the Si substrate 1 is heat-treated in, for example, a nitrogen atmosphere at a temperature of about 400° C. to about 1000° C., for example, about 600° C., and the residual Ti/Al is brought into ohmic contact with the compound semiconductor stacked structure 2. The heat treatment is sometimes unnecessary, provided that the ohmic contact between Ti/Al and the electron supply layer 2 d is obtained. Consequently, the source electrode 5 part of whose electrode material fills the electrode recesses 4A1, 2B1 and the drain electrode 6 part of whose electrode material fills the electrode recesses 4A2, 2B2 are formed.

The source electrode 5 and the drain electrode 6 are in contact with the electron supply layer 2 d and the cap layer 2 e and not in contact with the electron transit layer 2 b (intermediate layer 2 c).

The drain electrode 6 has a stepped structure on its lower surface and has a plurality of bottom surfaces, here two

bottom surfaces

6 a, 6 b along a transit direction of 2DEG, out of contact surfaces with the compound semiconductor stacked structure 2. The plural bottom surfaces are located at different distances from 2DEG, with the bottom surface closer to the source electrode 5 being more apart from 2DEG. In this embodiment, the bottom surface 6 a is more apart from 2DEG than the bottom surface 6 b.

In order to obtain the stepped-structure, in this embodiment, the two-stage stepped structure, of the lower surface, the drain electrode 6 fills also the inside of the electrode recess 4A2 of the protective insulating film 4, and a contact side surface 6 c close to the source electrode 5 out of contact side surfaces with the protective insulating film 4 is coupled to the bottom surface 6 a.

Incidentally, the source electrode may also have a stepped structure on its lower surface similarly to the drain electrode 6.

Subsequently, an electrode recess 45 for a gate electrode is formed in the protective insulating film 4 as illustrated in FIG. 3B.

In more detail, a resist is first applied on the surface of the compound semiconductor stacked structure 2. The resist is processed by lithography, whereby an opening from which a portion corresponding to a position where to form the gate electrode (planned electrode formation position), in the surface of the protective insulating film 4 is exposed is formed in the resist. Consequently, a resist mask having the opening is formed.

By using this resist mask, an about 40 nm upper portion of the protective insulating film 4 is dry-etched to be removed so that an about 20 nm lower portion of the protective insulating film 4 at the planned electrode formation position is left. Consequently, the electrode recess 4B for the gate electrode is formed in the protective insulating film 4.

In this embodiment, in the protective insulating film 4, the portion with an about 20 nm thickness left on a bottom portion of the electrode recess 4B functions as a gate insulating film.

Incidentally, the electrode recess for the gate electrode may be formed as a through trench from which the surface of the compound semiconductor stacked structure 2 is exposed, and the gate insulating film may be separately formed on the protective insulating film 4 so as to cover the surface. In this case, Al₂O₃with an about 2 nm to about 200 nm film thickness, for example, an about 10 nm film thickness is deposited by, for example, an ALD method (Atomic Layer Deposition), thereby forming the gate insulating film. For the deposition of Al₂O₃, a plasma CVD method, a sputtering method, or the like may be used, for instance, instead of the ALD method. Further, a nitride or an oxynitride of Al may be used instead of depositing Al₂O₃. Besides, for the formation of the gate insulating film, an oxide, a nitride, or an oxynitride of Si, Hf, Zr, Ti, Ta, and W may be deposited or some appropriately selected from these may be deposited in multilayer.

Subsequently, the gate electrode 7 is formed as illustrated in FIG. 3C.

In more detail, a resist mask for forming the gate electrode is first formed. Here, an eaves-structure two-layer resist suitable for a vapor deposition method and a liftoff method is used, for instance. This resist is applied on the protective insulating film 4, and an opening from which the portion corresponding to the electrode recess 4B, in the protective insulating film 4 is exposed is formed. Consequently, the resist mask having the opening is formed.

By using this resist mask, Ni/Au, for example, is deposited as an electrode material on the resist mask including the inside of the opening from which the portion corresponding to the electrode recess 4B, in the protective insulating film 4 is exposed, by, for example, the vapor deposition method. A thickness of Ni is about 30 nm and a thickness of Au is about 400 nm. The resist mask and Ni/Au deposited thereon are removed by the liftoff method. Consequently, the gate electrode 7 whose electrode material in its lower portion fills the inside of the electrode recess 4B and whose upper portion rides on the protective insulating film 4 is formed so that its cross section along a gate length is in a so-called overhanging shape. In the gate electrode 7, the gate length is, for example, about 0.5 μm and a gate width is, for example, about 400 μm.

Thereafter, through various processes such as the formation of an interlayer insulating film, the formation of wirings connected to the source electrode 5, the drain electrode 6, and the gate electrode 7, the formation of an upper protective film, and the formation of connection electrodes exposed to the uppermost surface, the AlGaN/GaN HEMT according to this embodiment is formed.

Regarding the AlGaN/GaN HEMT according to this embodiment, a potential state of the drain electrode at the time of the application of a high operating voltage (gate-drain voltage) was studied by simulation based on comparison with comparative examples. The results are presented in FIG. 4 to FIG. 6. FIG. 4 corresponds to a comparative example 1, FIG. 5 corresponds to a comparative example 2, and FIG. 6 corresponds to FIG. 3C of this embodiment, and each of them is a schematic cross-sectional view, with the drain electrode and its vicinity being enlarged. Concretely, isoelectric lines of 400 V and 300 V are illustrated, with the operating voltage being set to 400 V.

As illustrated in FIG. 4, an AlGaN/GaN HEMT of the comparative example 1 has a Si substrate 1, a compound semiconductor stacked structure 2, a protective insulating film 4, and so on similarly to this embodiment and a drain electrode 101 (and a source electrode) is formed so as to fill an electrode recess formed in the protective insulating film 4. The drain electrode 101 does not have a stepped structure on its lower surface and is in ohmic contact with a surface of a cap layer 2 e.

In the comparative example 1, an interval d1 between the isoelectric line of 400 V and the isoelectric line of 300 V in a portion of 2DEG is very narrow. This means that electric field concentration is occurring on an electrode end 101A of the drain electrode 101. This electric field concentration causes the simultaneous generation of electrons and holes due to an avalanche effect, and the electrons and the holes further continuously cause the cumulative generation of electrons and holes to rapidly increase a current, so that a breakdown occurs in the drain electrode 101.

As illustrated in FIG. 5, an AlGaN/GaN HEMT of the comparative example 2 has a Si substrate 1, a compound semiconductor stacked structure 2, a protective insulating film 4, and so on similarly to this embodiment and a drain electrode 102 (and a source electrode) is formed so as to fill an electrode recess formed in the protective insulating film 4, a cap layer 2 e, and an electron supply layer 2 d. The drain electrode 102 does not have a stepped structure on its lower surface and is in ohmic contact with the electron supply layer 2 d.

In the comparative example 2, an interval d2 between the isoelectric line of 400 V and the isoelectric line of 300 V in a portion of 2DEG is also very narrow as in the comparative example 1. This means that electric field concentration is occurring on an electrode end 102A of the drain electrode 102. This electric field concentration causes the simultaneous generation of electrons and holes due to an avalanche effect, and the electrons and the holes further continuously cause the cumulative generation of electrons and holes to rapidly increase a current, so that a breakdown occurs in the drain electrode 102.

In this embodiment, an interval d3 between the isoelectric line of 400 V and the isoelectric line of 300 V in a portion of DEG is far wider than the intervals d1, d2 as illustrated in FIG. 6. The drain electrode 6 in this embodiment has the two-stage stepped structure on its lower surface, and the bottom surface 6 a is more apart from 2DEG than the bottom surface 6 b. With this structure, the electric field concentration occurs on two electrode ends 6A, 6B of the drain electrode 6. Since the electric field concentration is decided by a degree of depletion of 2DEG, the electric field concentration is distributed to the two electrode ends 6A, 6B to be alleviated. Consequently, the avalanche effect is inhibited and the breakdown of the drain electrode 6 is prevented.

As described above, according to this embodiment, a highly reliable AlGaN/GaN HEMT that prevents an avalanche effect which is the simultaneous generation of holes and electrons, to inhibit snap-back and realizes a stable high withstand voltage to enable performance improvement and yield improvement is realized.

Second Embodiment

In this embodiment, a structure and a manufacturing method of an AlGaN/GaN HEMT are disclosed as in the first embodiment, but a stepped structure of a drain electrode is different from that of the first embodiment. Note that the same constituent members and so on as those of the first embodiment will be denoted by the same reference signs and a detailed description thereof will be omitted.

FIG. 7A to FIG. 7C and FIG. 10A to FIG. 100 are schematic cross-sectional views illustrating main steps of the method of manufacturing the AlGaN/GaN HEMT according to the second embodiment.

In this embodiment, the steps in FIG. 1A to FIG. 2A are first performed as in the first embodiment. At this time, electrode recesses 4A1, 4A2 for a source electrode and a drain electrode are formed in a protective insulating film 4. A state at this time is illustrated in FIG. 7A.

Subsequently, as illustrated in FIG. 7B, a resist mask 21 is formed.

In more detail, a resist is applied on the whole surface. The resist is processed by lithography, whereby an opening 21 a from which the electrode recess 4A1 for the source electrode in a surface of a cap layer 2 e and an opening 21 b from which part of the electrode recess 4A2 for the drain electrode in the surface of the cap layer 2 e is exposed are formed in the resist. Consequently, the resist mask 21 having the

openings

21 a, 21 b is formed.

Subsequently, as illustrated in FIG. 7C, electrode recesses 2C1, 2C2 are formed in a compound semiconductor stacked structure 2.

By using the resist mask 21, the cap layer 2 e and upper layer portions of an electron supply layer 2 d are dry-etched to be removed so that lower layer portions of the electron supply layer 2 d are left. Consequently, in the compound semiconductor stacked structure 2, the electrode recess 2C1 from which a region where to form the source electrode in the lower layer portion of the electron supply layer 2 d is exposed and the electrode recess 2C2 from which a region where to form the drain electrode in the lower layer portion of the electron supply layer 2 d is exposed are formed. For the dry-etching, chlorine-based etching gas such as Cl₂, for example, is used.

The resist mask 21 is removed by ashing using oxygen plasma or by wetting using a predetermined chemical solution.

Subsequently, as illustrated in FIG. 8A, a resist mask 22 is formed.

In more detail, a resist is applied on the whole surface. The resist is processed by lithography, whereby an opening 22 a from which part of the electrode recess 4B2 for the drain electrode in the surface of the cap layer 2 e is exposed is formed in the resist. Consequently, the resist mask 22 having the opening 22 a is formed.

Subsequently, as illustrated in FIG. 88, an electrode recess 2D is formed in the compound semiconductor stacked structure 2.

By using the resist mask 22, an upper layer portion of the electron supply layer 2 d is dry-etched to be removed so that the lower layer portion of the electron supply layer 2 d is left. Consequently, in the compound semiconductor stacked structure 2, the electrode recess 2D from which a region where to form the drain electrode in the lower layer portion of the electron supply layer 2 d is exposed is formed. For the dry-etching, chlorine-based etching gas such as Cl₂, for example, is used.

Subsequently, as illustrated in FIG. 8C, an electrode recess 2E is formed in the compound semiconductor stacked structure 2.

By using the resist mask 22 again, the electrode recess 2D of the electron supply layer 2 d is wet-etched. A side surface of the electrode recess 2D becomes in a forward tapered shape with a predetermined angle (for example, about 45°), and the electrode recess 2E is formed. As a chemical solution for the wet etching, sulfuric acid/hydrogen peroxide is used. Alternatively, by using NMDW (manufactured by Tokyo Ohka Kogyo Co., Ltd.) or the like being an alkaline developing solution, the side surface in the forward tapered shape is similarly formed in the electrode supply layer 2 d.

Subsequently, the resist mask 22 is removed as illustrated in FIG. 9A.

The resist mask 22 is removed by ashing using oxygen plasma or by wet etching using a predetermined chemical solution.

Consequently, the electrode recess 2C1 from which the region where to form the source electrode in the lower layer portion of the electron supply layer 2 d is exposed and the electrode recesses 2C2, 2E from which the region where to form the drain electrode in the lower layer portion of the electron supply layer 2 d is exposed are formed in the compound semiconductor stacked structure 2.

Subsequently, the source electrode 23 and the drain electrode 24 are formed as illustrated in FIG. 9B.

In more detail, a resist is applied on a surface of the protective insulating film 4. The resist is processed by lithography, whereby openings from which the electrode recesses 4A1, 2C1 for the source electrode and the electrode recesses 4A2, 2C2, 2E for the drain electrode are exposed are formed in the resist. Consequently, a resist mask having the openings is formed.

By using this resist mask, for example, Ti/Al is deposited as an electrode material on the resist mask including the inside of the openings from which the electrode recesses 4A1, 2C1 and the electrode recesses 4A2, 2C2, 2E are exposed, by a vapor deposition method, for instance. A thickness of Ti is about 30 nm and a thickness of Al is about 200 nm. The resist mask and Ti/Al deposited thereon are removed by a liftoff method. Thereafter, the Si substrate 1 is heat-treated in, for example, a nitrogen atmosphere at a temperature of about 400° C. to about 1000° C., for example, about 600° C., and the residual Ti/Al is brought into ohmic contact with the compound semiconductor stacked structure 2. The heat treatment is sometimes unnecessary, provided that the ohmic contact between Ti/Al and the electron supply layer 2 d is obtained. Consequently, the source electrode 23 part of whose electrode material fills the electrode recesses 4A1, 2C1 and the drain electrode 24 part of whose electrode material fills the electrode recesses 4A2, 2C2, 2E are formed.

The source electrode 23 and the drain electrode 24 are in contact with the electron supply layer 4 d and the cap layer 4 e and not in contact with the electron transit layer 4 b (intermediate layer 4 c).

The drain electrode 24 has a stepped structure on its lower surface and has a plurality of bottom surfaces, here three

bottom surfaces

24 a, 24 b, 24 c along a transit direction of 2DEG, out of contact surfaces with the compound semiconductor stacked structure 2. The plural bottom surfaces are located at different distances from 2DEG, with the bottom surface closer to the source electrode 23 being more apart from 2DEG. In this embodiment, the bottom surface 24 a is more apart from 2DEG than the bottom surface 24 b, and the bottom surface 24 b is more apart from 2DEG than the bottom surface 24 c.

In the drain electrode 24, a side surface 24 d coupling the bottom surfaces 24 b, 24 c out of the contact surfaces with the compound semiconductor stacked structure 2 is in a tapered shape so that its portion more apart from the source electrode 23 comes closer to 2DEG.

In order to obtain the stepped-structure, in this embodiment, the three-stage stepped structure, of the lower surface, the drain electrode 24 fills also the inside of the electrode recess 4A2 of the protective insulating film 4, and the contact side surface 24 e close to the source electrode 23 out of contact side surfaces with the protective insulating film 4 is coupled to the bottom surface 24 a.

Incidentally, the source electrode may also have the stepped structure on its lower surface similarly to the drain electrode 24.

Subsequently, an electrode recess 4B for a gate electrode is formed in the protective insulating film 4 as illustrated in FIG. 10A.

In more detail, a resist is first applied on a surface of the compound semiconductor stacked structure 2. The resist is processed by lithography, whereby an opening from which a portion corresponding to a position where to form the gate electrode (planned electrode formation position), in the surface of the protective insulating film 4 is exposed is formed in the resist. Consequently, a resist mask having the opening is formed.

The resist mask is removed by asking using oxygen plasma or by wetting using a predetermined chemical solution.

Incidentally, the electrode recess for the gate electrode may be formed as a through trench from which the surface of the compound semiconductor stacked structure 2 is exposed, and the gate insulating film may be separately formed on the protective insulating film 4 so as to cover the surface. In this case, Al₂O₃with an about 2 nm to about 200 nm film thickness, for example, an about 10 nm film thickness is deposited by, for example, an ALD method (Atomic Layer Deposition), thereby forming the gate insulating film. For the deposition of Al₂O₃, a plasma CVD method, a sputtering method, or the like may be used, for instance, instead of the ALD method. Further, instead of depositing Al₂O₃, a nitride or an oxynitride of Al may be used. Besides, for the formation of the gate insulating film, an oxide, a nitride, or an oxynitride of Si, Hf, Zr, Ti, Ta, and W may be deposited or some appropriately selected from these may be deposited in multilayer.

Subsequently, the gate electrode 7 is formed as illustrated in FIG. 10B.

Thereafter, through various processes such as the formation of an interlayer insulating film, the formation of wirings connected to the source electrode 23, the drain electrode 24, and the gate electrode 7, the formation of an upper protective film, and the formation of connection electrodes exposed to the uppermost surface, the AlGaN/GaN HEMT according to this embodiment is formed.

In this embodiment, the drain electrode 24 has the three-stage stepped structure on its lower surface, and the bottom surface 24 a is more apart from 2DEG than the bottom surface 24 b, and the bottom surface 24 b is more apart from 2DEG than the bottom surface 24 c. With this structure, the electric field concentration occurs on three electrode ends 24A, 24B, 24C of the drain electrode 24. Since the electric field concentration is decided by a degree of depletion of 2DEG, the electric field concentration is distributed to the three electrode ends 24A, 24B, 24C to be alleviated. Further, the side surface 24 d is in the tapered shape so that its portion more apart from the gate electrode 7 becomes closer to 2DEG, which more alleviates the electric field concentration. Consequently, the avalanche effect is surely inhibited and the breakdown of the drain electrode 24 is prevented.

Third Embodiment

In this embodiment, a structure and a manufacturing method of an AlGaN/GaN HEMT are disclosed as in the second embodiment, but a gate electrode and its lower layer structure are different from those of the second embodiment. Note that the same constituent members and so on as those of the first and second embodiments will be denoted by the same reference signs and a detailed description thereof will be omitted.

FIG. 11A to FIG. 11C and FIG. 12A to FIG. 12C are schematic cross-sectional views illustrating main steps of the method of manufacturing the AlGaN/GaN HEMT according to the third embodiment.

First, as illustrated in FIG. 11A, a compound semiconductor stacked structure 2 is formed on, for example, a Si substrate 1 as a growth substrate. As the growth substrate, a SiC substrate, a sapphire substrate, a GaAs substrate, a GaN substrate, or the like may be used instead of the Si substrate. Conductivity of the substrate may be either semi-insulating or conductive.

The compound semiconductor stacked structure 2 includes a buffer layer 2 a, an electron transit layer 2 b, an intermediate layer 2 c, an electron supply layer 2 d, a cap layer 2 e, and a p-type semiconductor layer 2 f.

In more detail, on the Si substrate 1, the following compound semiconductors are grown by, for example, a MOVPE method. A MBE method or the like may be used instead of the MOVPE method.

On the Si substrate 1, AlN with an about 100 nm thickness, i (intentionally undoped)-GaN with an about 1 μm thickness, i-AlGaN with an about 5 nm thickness, n-AlGaN with an about 30 nm thickness whose Al composition is, for instance, about 20%, n-GaN with an about 3 nm thickness, and p-GaN with a predetermined thickness are sequentially grown. Consequently, the buffer layer 2 a, the electron transit layer 2 b, the intermediate layer 2 c, the electron supply layer 2 d, the cap layer 2 e, and the p-type semiconductor layer 2 f are formed. As the buffer layer 2 a, AlGaN may be used instead of AlN, or GaN may be grown by low-temperature growth.

In order to grown p-GaN of the p-type semiconductor layer 2 f, Cp₂Mg gas containing, for example, Mg as p-type impurities is added to the source gas at a predetermined flow rate, so that GaN is doped with Mg to a predetermined doping concentration.

Subsequently, the p-type semiconductor layer 2 f is processed as illustrated in FIG. 11B.

In more detail, a resist is applied on the p-type semiconductor layer 2 f. The resist is processed by lithography, whereby a resist mask opening a region where to form a gate electrode is formed.

By using this resist mask, the p-type semiconductor layer 2 f is dry-etched until a surface of the cap layer 2 e is exposed. For the dry etching, chlorine-based etching gas such as Cl₂, for example, is used. Consequently, the p-type semiconductor layer 2 f remains on the region where to form the gate electrode on the cap layer 2 e.

Two-dimensional electron gas (2DEG) being transit electrons is generated in the vicinity of an interface of the electron transit layer 2 b, with the electron supply layer 2 d (to be exact, the intermediate layer 2 c) except a region under and aligned with the p-type semiconductor layer 2 f. This 2DEG is generated based on a difference in lattice constant between a compound semiconductor (here GaN) of the electron transit layer 2 b and a compound semiconductor (here AlGaN) of the electron supply layer 2 d. In this embodiment, due to the presence of the p-type semiconductor layer 2 f, 2DEG disappears at the power-off time in the region under and aligned with the p-type semiconductor layer 2 f. Consequently, a so-called normally-off operation is realized.

Subsequently, element isolation structures 3 are formed by the same step as that in FIG. 1B of the first embodiment, as in the second embodiment.

Subsequently, as illustrated in FIG. 11C, a protective insulating film 4 is formed.

In more detail, SiN with a thickness of about 30 nm to about 500 nm, for example, about 60 nm is deposited on the compound semiconductor stacked structure 2 by a plasma CVD method, a sputtering method, or the like so as to fill element isolation recesses 2A on the element isolation structures 3 and so as to cover the p-type semiconductor layer 2 f. Consequently, the protective insulating film 4 is formed.

Subsequently, the same steps as those in FIG. 7A to FIG. 9B are executed as in the second embodiment. At this time, a source electrode 23 part of whose electrode material fills electrode recesses 4A1, 2C1 and a drain electrode 24 part of whose electrode material fills electrode recesses 4A2, 2C2, 2E are formed.

Subsequently, an electrode recess 4C for the gate electrode is formed in the protective insulating film 4 as illustrated in FIG. 12A.

In more detail, a resist is first applied on a surface of the protective insulating film 4. The resist is processed by lithography, whereby an opening from which a portion corresponding to the p-type semiconductor layer 2 f, in the surface of the protective insulating film 4 is exposed is formed in the resist. Consequently, a resist mask having the opening is formed.

By using this resist mask, the protective insulating film 4 is dry-etched until a surface of the p-type semiconductor layer 2 f is exposed. Consequently, the electrode recess 4C for the gate electrode is formed in the protective insulating film 4.

Subsequently, the gate electrode 25 is formed as illustrated in FIG. 12B.

In more detail, a resist mask for forming the gate electrode is first formed. Here, an eaves-structure two-layer resist suitable for a vapor deposition method and a liftoff method is used, for instance. This resist is applied on the protective insulating film 4, and an opening from which the portion corresponding to the electrode recess 4C, in the protective insulating film 4 is exposed is formed. Consequently, the resist mask having the opening is formed.

By using this resist mask, Ni/Au, for example, is deposited as an electrode material on the resist mask including the inside of the opening from which the portion corresponding to the electrode recess 4C, in the protective insulating film 4 is exposed, by, for example, the vapor deposition method. A thickness of Ni is about 30 nm and a thickness of Au is about 400 nm. The resist mask and Ni/Au deposited thereon are removed by the liftoff method. Consequently, the gate electrode 25 whose electrode material in its lower portion fills the inside of the electrode recess 4C to be in contact with the surface of the p-type semiconductor layer 2 f and whose upper portion rides on the protective insulating film 4 is formed so that its cross section along a gate length is in a so-called overhanging shape. In the gate electrode 25, the gate length is, for example, about 0.5 μm and a gate width is, for example, about 400 μm.

Thereafter, through various processes such as the formation of an interlayer insulating film, the formation of wirings connected to the source electrode 23, the drain electrode 24, and the gate electrode 25, the formation of an upper protective film, and the formation of connection electrodes exposed to the uppermost surface, the AlGaN/GaN HEMT according to this embodiment is formed.

In this embodiment, the drain electrode 24 has the three-stage stepped structure on its lower surface, and the bottom surface 24 a is more apart from 2DEG than the bottom surface 24 b, and the bottom surface 24 b is more apart from 2DEG than the bottom surface 24 c. With this structure, the electric field concentration occurs on three electrode ends 24A, 24B, 24C of the drain electrode 24. Since the electric field concentration is decided by a degree of depletion of 2DEG, the electric field concentration is distributed to the three electrode ends 24A, 24B, 24C to be alleviated. Further, a side surface 24 d is in a tapered shape so that its portion more apart from the gate electrode 25 becomes closer to 2DEG, which more alleviates the electric field concentration. Consequently, the avalanche effect is surely inhibited and the breakdown of the drain electrode 24 is prevented.

Regarding the AlGaN/GaN HEMTs according to the above-described first, second, and third embodiments, a change in a drain current when a drain voltage was changed in a pinch-off state was studied by simulation based on comparison with comparative examples. The results are illustrated in FIG. 13. A comparative example 1 is the AlGaN/GaN HEMT in FIG. 4, and a comparative example 2 is the AlGaN/GaN HEMT in FIG. 5.

In the comparative examples 1, 2, it is seen that holes and electrons are simultaneously generated, and immediately before the breakdown of a drain electrode, snap-back which is a rapid decrease of the drain voltage occurs to promote the breakdown of the drain electrode. On the other hand, in the first, second, and third embodiments, it has been confirmed that the generation of holes is inhibited and no snap-back occurs, enabling a stable high withstand voltage over 600 V.

Fourth Embodiment

In this embodiment, a power supply circuit to which one kind of the AlGaN/GaN HEMT selected from the first to third embodiments is applied is disclosed.

FIG. 14 is a connection diagram illustrating a schematic structure of the power supply circuit according to the fourth embodiment.

The power supply circuit according to this embodiment includes a high-voltage primary-side circuit 31, a low-voltage secondary-side circuit 32, and a transformer 33 disposed between the primary-side circuit 31 and the secondary-side circuit 32.

The primary-side circuit 31 includes an AC power source 34, a so-called bridge rectifying circuit 35, and a plurality of (four here) switching

elements

36 a, 36 b, 36 c, 36 d. Further, the bridge rectifying circuit 35 has a switching element 36 e.

The secondary-side circuit 32 includes a plurality of (three here) switching

elements

37 a, 37 b, 37 c.

In this embodiment, the switching

elements

36 a, 36 b, 36 c, 36 d, 36 e of the primary-side circuit 31 are each one kind of the AlGaN/GaN HEMT selected from the first to third embodiments. On the other hand, the switching

elements

37 a, 37 b, 37 c of the secondary-side circuit 32 are each an ordinary MIS•FET using silicon.

In this embodiment, a highly reliable AlGaN/GaN HEMT that prevents an avalanche effect which is the simultaneous generation of holes and electrons, to inhibit snap-back and realizes a stable high withstand voltage to enable performance improvement and yield improvement is applied to the power supply circuit. Consequently, a highly reliable and high-power power supply circuit is realized.

Fifth Embodiment

In this embodiment, a high-frequency amplifier to which one kind of the AlGaN/GaN HEMT selected from the first to third embodiments is applied is disclosed.

FIG. 15 is a connection diagram illustrating a schematic structure of the high-frequency amplifier according to the fifth embodiment.

The high-frequency amplifier according to this embodiment includes a digital pre-distortion circuit 41,

mixers

42 a, 42 b, and a power amplifier 43.

The digital pre-distortion circuit 41 compensates nonlinear distortion of an input signal. The mixer 42 a mixes the input signal whose nonlinear distortion is compensated and an AC signal. The power amplifier 43 amplifies the input signal mixed with the AC signal, and has one kind of the AlGaN/GaN HEMT selected from the first to third embodiments. In FIG. 15, by, for example, changing of the switches, an output-side signal can be mixed with the AC signal by the mixer 42 b, and the resultant can be sent out to the digital pre-distortion circuit 41.

In this embodiment, a highly reliable AlGaN/GaN HEMT that prevents an avalanche effect which is the simultaneous generation of holes and electrons, to inhibit snap-back and realizes a stable high withstand voltage to enable performance improvement and yield improvement is applied to the high-frequency amplifier. Consequently, a highly reliable and high-withstand-voltage high-frequency amplifier is realized.

Other Embodiments

In the first to fifth embodiments, the AlGaN/GaN HEMT is exemplified as the compound semiconductor device. As the compound semiconductor device, the present invention is applicable to the following HEMTs, besides the AlGaN/GaN HEMT.

Example 1 of Other HEMT

In this example, an InAlN/GaN HEMT is disclosed as the compound semiconductor device.

InAlN and GaN are compound semiconductors whose lattice constants can be made close to each other by the composition. In this case, in the above-described first to fifth embodiments, the electron transit layer is made of i-GaN, the intermediate layer is made of i-InAlN, the electron supply layer is made of n-InAlN, and the cap layer is made of n-GaN. Further, in this case, almost no piezoelectric polarization occurs, and therefore, two-dimensional electron gas is generated mainly by spontaneous polarization of InAlN.

According to this example, a highly reliable and high-withstand-voltage InAlN/GaN HEMT that prevents an avalanche effect which is the simultaneous generation of holes and electrons, to inhibit snap-back and realizes a stable high withstand voltage to enable performance improvement and yield improvement is realized, similarly to the above-described AlGaN/GaN HEMT.

Example 2 of Other HEMT

In this example, an InAlGaN/GaN HEMT is disclosed as the compound semiconductor device.

GaN and InAlGaN are compound semiconductors, with the latter capable of having a smaller lattice constant than that of the former by the composition. In this case, in the above-described first to fifth embodiments, the electron transit layer is made of i-GaN, the intermediate layer is made of i-InAlGaN, the electron supply layer is made of n-InAlGaN, and the cap layer is made of n-GaN.

According to the above-described various embodiments, a highly reliable compound semiconductor device that prevents an avalanche effect which is the simultaneous generation of holes and electrons, to inhibit snap-back and realizes a stable high withstand voltage to enable performance improvement and yield improvement is realized.

All examples and conditional language provided herein are intended for the pedagogical purposes of aiding the reader in understanding the invention and the concepts contributed by the inventor to further the art, and are not to be construed as limitations to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although one or more embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.

Claims

What is claimed is:

1. A compound semiconductor device comprising:

a compound semiconductor layer; and

a pair of electrodes formed on an upper side the compound semiconductor layer,

wherein one of the pair of electrodes has three bottom surfaces along transit electrons out of contact surfaces with the compound semiconductor layer, and the three bottom surfaces are located at different distances from the transit electrons, with the bottom surface closest to the other of the pair of electrodes being more apart from the transit electrons; and wherein, in the one of the pair of electrodes, a side surface coupling predetermined adjacent two of the bottom surfaces out of the contact surfaces is in a tapered shape whose portion more apart from the other of the pair of electrodes becomes closer to the transit electrode.

2. The compound semiconductor device according to claim 1, further comprising

a protective insulating film covering the compound semiconductor layer,

wherein, in the one of the pair of electrodes, a contact side surface close to the other of the pair of electrodes out of contact side surfaces with the protective insulating film is coupled to the bottom surface.

3. The compound semiconductor device according to claim 1,

wherein the compound semiconductor layer has an electron transit layer in which the transit electrons are generated and an electron supply layer formed above the electron transit layer, and

wherein the pair of electrodes are in contact with the electron supply layer and not in contact with the electron transit layer.

4. The compound semiconductor device according to claims 1, further comprising:

another electrode formed between the pair of electrodes, above the compound semiconductor layer; and

a p-type semiconductor layer formed between the compound semiconductor layer and the other electrode.

5. A method of manufacturing a compound semiconductor device comprising:

forming a compound semiconductor layer; and

forming a pair of electrodes on an upper side the compound semiconductor layer,

wherein one of the pair of electrodes has three bottom surfaces along transit electrons out of contact surfaces with the compound semiconductor layer, and the three bottom surfaces are located at different distances from the transit electrons, with the bottom surface closer to the other of the pair of electrodes being more apart from the transit electrons; and wherein, in the one of the pair of electrodes, a side surface coupling predetermined adjacent two of the bottom surfaces out of the contact surfaces is in a tapered shape whose portion more apart from the other of the pair of electrodes becomes closer to the transit electrode.

6. The method of manufacturing the compound semiconductor device according to claim 5, further comprising

forming a protective insulating film covering the compound semiconductor layer,

7. The method of manufacturing the compound semiconductor device according to claim 5,

8. The method of manufacturing the compound semiconductor device according to claim 5, further comprising:

forming another electrode between the pair of electrodes, above the compound semiconductor layer; and

forming a p-type semiconductor layer between the compound semiconductor layer and the other electrode.